Carbonbond Carbon Fiber

The MDTI Carbonbond is a carbon fiber fabric used to strengthen structural elements. The fabric is composed of bi-directional carbon fibers that will be field laminated using MDTI Epoxy saturating MDTI#400.

The Carbonbond System is an ideal choice for foundation damage of two inches or less in width because they provide maximum stability repair without requiring invasive drilling or excavation in a basement. Woven fiber comes in uni-directional and bi-directional options, allowing for the resistance of movement in one direction or two directions, respectively. The type of carbon fiber for your repair will be dependent upon the severity and characteristic of the offending crack.

An added steel angle at the top of the wall effectively concludes the repair. The finished product can easily be painted over to blend in with the space and contribute to a clean, comfortable living area. This fix is permanent, as carbon fiber repairs require zero maintenance.

Suggested Uses

  • Increasing the in-plane, out-of-plane and ductility of unreinforced brick and masonry buildings
  • Stabilizing industrial chimneys against seismic and wind forces
  • Increasing the in-plane and out-of-plane strengths of concrete tilt-up walls

Installation of Carbonbond

Installation can be accomplished with a team of 1-3 members, and only relies on a few simple tools. First the crack is injected with either epoxy or urethane, depending upon the condition of the fracture, then concealed with carbon fiber strips, which reinforce the wall and prevent further damage. With no welding, digging, or excavating required, the set-up, installation, and cleanup processes are minimally disruptive to the home.

Directions for Use

Prepare surface, mix epoxies thoroughly and saturate and apply the wraps.

Surface Preparation

The preparation of surfaces to receive the MDTI Carbon Bond must be given careful attention, as the bonding capability of the epoxy for a given application is primarily dependent on proper surface preparation. Concrete surfaces must be structurally sound and free from contaminants such as dust, oil or dirt. Surfaces must be shot blasted or mechanically abraded to achieve a minimum 5-mil profile. Remove fins, sharp edges, and protrusions that may trap air behind the installed wrap. Coated surfaces must be mechanically cleaned and abraded with 60-80 mesh sandpaper and approved by the manufacturer before applying adhesive. A calcium chloride test is recommended and hydrostatic pressure must be <5psi before epoxy coatings application. Repair all damaged concrete, spalls and irregular surfaces and fill uneven surfaces with MDTI putty mix.

Mixing Epoxy

Mixing Epoxy thorough and complete mixing is critical, a MDTI mixer is recommended.

WARNING: Epoxies develop heat during mixing and curing. To keep temperature rise to a minimum, a high surface area to volume ratio during mixing is recommended. For manual mixing, each mix volume should be kept to 5 gallons or less. For automated mixing follow the equipment manufacturer’s instructions.

First, mix each component separately. Proportion each component at their specified ratios and mix using a slow-speed drill with jiffy paddle at 400-600 RPM for 3-5 minutes until a consistent color is achieved. No stripes, streaks or color variation should be visible. Use an up and down motion, scraping the mixing container sides and bottom. Mix no more material than may be applied within the specified pot life of the epoxy.

Application of Wraps

For Dry Lay-Up

  1. Using a roller or sprayer, apply a coat of MDTI primer onto the prepared surface.
  2. Apply a coat of saturating resin (MDTI#400) to the still tacky primed surface.
  3. Press the dry fabric (wrap) onto the surface and using a roller, apply pressure to the surface of the fabric to ensure good bonding to the substrate and to roll out any entrapped air before the epoxy sets. Smooth the fabric from center to the edge to remove air pockets. Good saturation of the fabric is indicated by some epoxy oozing out to the external face of the fabric and wetting the fibers on the external face.
  4. Apply a final coat of saturating resin on top of the fabric using a roller or by using a sprayer (spiked roller can be used to remove any entrapped air).
  5. Apply paint or protective coating if desired while the final resin coat is still tacky. Fully cured resin must be scuffed for optimum bonding to the paint or protective coating When multi-layer wraps are used, each individual layer shall be firmly bedded and adhered to the preceding layer or the substrate before the epoxy on the preceding layer is fully cured and is still tacky.

For Wet Lay-Up

  1. Using a roller or sprayer, apply a coat of MDTI primer onto the prepared surface.
  2. (For applications requiring Tack Coat): Apply the tack coat (MDTI#4) to the surface using a trowel or putty knife, filling out all pores and leaving a 20-mil thick coating (measured wet) of the tack coat on the surface.
  3. Press the resin-saturated fabric on to the substrate and using a roller apply pressure to the surface of the fabric to ensure good bonding to the substrate and to roll out any trapped air before the epoxy sets. Smooth the fabric from center to the edge to remove air pockets.
  4. Apply paint or protective coating, if desired while the final resin coat is still tacky. Dry resin must be scuffed for optimum bonding to the paints or protective coatings.

Curing of Wraps

Curing times and temperature for wrap shall be maintained for the designated formulation used, according to the instructions supplied with the epoxy. The cured composite should have a uniform thickness and density, and lack porosity.

Procedure Modifications

Due to environmental factors affecting quality of work, installation procedures may be modified to achieve maximum results. Procedure modifications shall be discussed with and approved by the Engineer of record prior to implementing the modifications.

Conditions to Avoid

  • Do not apply to concrete with temperature outside of application temperature range
  • Do not apply to concrete less than 30 days old
  • Do not apply to concrete with curing or sealing membranes
  • Do not apply to base concrete at a temperature less than 45°F

Advantages of Carbon Fiber from MDTI

  • Corrosion resistant – minimizing costs and wear
  • Adds only a 1/16 of an inch to the repaired surface
  • Light weight (½ the weight of aluminum)
  • Reduces installation time since heavy equipment and welding is eliminated
  • Low thermal expansion
  • Flexible wrap conforms to any shape
  • Minimal change to structure’s shape, weight and appearance
  • Used for increasing strength, stiffness, fatigue resistance of damaged structures up to, and at times beyond its initial design value
  • Used for shear, confinement or flexural strengthening
  • Minimal disruption and noise
  • Economical
  • Reduces hazards, damage and secondary damage resulting from seismic incidents and falling debris

Typical Data

  • Storage Conditions – Store dry at 40°F-95°F
  • Color – Black
  • Primary Fiber Direction – Bi-Directional
  • Weight Per Square Yard (BC25T) – 25 oz.

Packaging

  • Product – BC25T
  • Description – 25 oz/sq yd Bi-directional
  • Primary Fiber – Carbon
  • Standard Roll Length – 100 yds
  • Available Widths – 50″
  • Roll Sq. Feet – 2000 sq ft

*Minimum order quantities apply; consult MDTI representative for more information. Special ordering may be possible after consulting with a representative of MDTI. These figures represent standard sizes and are not guaranteed as they may be subject to change at any time.
*Contact MDTI representative for special order.

Commercial Applications

Applications include Concrete columns, walls, bridges, damns, and floor slabs; tilt-up, and masonry walls; parking structures; and steel beams and tanks.

Residential Wall Repair

Carbonbond can be utilized in residential applications including basement walls, interior cracks, and exterior foundation walls.